UNIT -1 (QUALITY) Quality Quality Quality

Quality Quality Quality Quality Quality Quality Quality Quality Quality Quality Quality Quality Quality Quality Quality Quality Quality Quality

1. Course Code MEPC-27/PRPC-29 Course Title Statistical Quality Control And Reliability Number of Credits 4 Prerequisites (Course code) Production Technology-II (MEPC22) Course Type EPR COURSE LEARNING OBJECTIVES: 1 . To understand the fundamentals of Quality, Economics of Quality and T.Q.M. 2. To understand the basic statistical concepts, decision preparatory of the control charts, their applications and Process Capability Behaviour. 3. To understand the concepts of Acceptance Sampling, Sampling Plans and their applications. 4. To understand the Reliability and its relationship with Availability and Maintainability. COURSE CONTENTS : UNIT-I Introduction Quality – Basic Concepts: Issues in Quality, factors affecting quality, creating quality by design, product development cycle, economics of quality, Various definitions, ISO definition of quality and its meanings, and various phases till TQM and its meaning to industries, customers and employees, contribution of quality gurus etc. towards quality concepts. Total Quality management: its scope application and implementation. Quality circle: its objectives, structure and techniques, Variability concept in manufacturing –cycle, fishbone diagrams, charts in time philosophy. (8 hrs) UNIT-II Quality Control Basic statistical concepts, various types of distributions, General theory X and R chart. Decision preparatory to the control charts. Trial control limits. Selection of sub-groups. Charts with variable subgroups. Reject and Revoke, limits for average on X charts, modified control limits, specification limits, practical limitations. Control charts for fraction defectives, calculation and plotting of control limits, sensitivity of p chart, applications, and Control charts for Defects, difference between defect and defective, calculation and plotting of control limits, application. Pi charts and u charts, plotting of charts. Tests for various control charts. Tests for various control charts, process capability- inherent and potential capability. (12 hrs)

2. UNIT- III Acceptance Sampling Purpose, Acceptance by Attributes, single sampling plans. O.C.curve selection of sampling plans, Acceptance number, Type A and Type B errors, O.C. curves, Double sampling plan and its analysis, Multiple and sequential sampling , A.O.Q.L., Acceptance sampling plans under risk. Design of various sampling plans, Dodge- Roming type system for acceptance sampling by attributes (use of various tables). Determination of process average, Acceptance sampling by variables. ( 10 hrs ) UNIT- IV Reliability Concepts of Reliability, factors affecting Reliability, pattern of Failure, Mean Time to Failure, Fundamental of Statistical Concepts, consideration of Reliability in Series and Parallel System, effect of Redundancy and Reliability, method of Reliability Evaluation, Reliability Optimization, Availability and Maintainability, means to improve Reliability, Reliability Control during manufacture. (10 hrs ) Course Outcomes: Students will be able to understand the fundamentals of Quality, Economics of Quality and T.Q.M. Students will be able to understand the basic statistical concepts, decision preparatory of the control charts their applications and Process Capability Behaviour. Students will be able to understand the concepts of Acceptance Sampling, Sampling Plans and their applications Students will be able to understand the Reliability and its relationship with Availability and Maintainability Reference Books: Statistical Quality Control by Grant and Leaven, McGraw-Hill. Quality Control and Reliability by Mahajan , Dhanpat Rai . Quality Control by Hansen, Prentice-Hall. Statistical Quality Control, a modern introduction by Douglas C. Montgomery. Elementary Statistical Quality Control, 2nd Edition - CRC Press Book By. John T. Burr. Total Quality Management – An Integrated Approach  Paperback – 2016 by  DR. Kiran   Handbook of Reliability Engineering and Management Book by Clyde F. Coombs Jr. and William Grant Ireson .

3. Quality

4. Quality, as it applies to an object (product, service, process), is defined as the “degree to which a set of inherent characteristics (attributes) of the object satisfies a set of requirements.” Therefore, the quality of an object is determined by comparing a predetermined set of characteristics against a set. 

5. Purpose of a quality The purpose of a quality management system is  to ensure every time a process is performed, the same information, methods, skills and controls are used and applied in a consistent manner . If there are process issues or opportunities, this is then fed into the quality management system to ensure continuous improvement.

6. Issues in Quality 1 : The Culture of Managing by Departments. 2: Resistance to Technological Innovation. 3: Upper Management's Unwillingness to Provide Additional Resources and Time. 4: Increasing Complexity of the Supply Chain.

7. Factors affecting Quality Market : Because of technology advancement, we could see many new products to satisfy customer wants. Money : The increased global competition necessitates huge outlays for new equipment’s and process. Management : Because of the increased complex structure of business organization, the quality related responsibilities lie with persons at different levels in the organization.

8. Men: The rapid growth in technical knowledge leads to development of human resource with different specialization. Motivation : If we fix the responsibility of achieving quality with each individual in the organization with proper motivation techniques, there will not be any problem in producing the designed quality products. Materials : Selection of proper materials to meet the desired tolerance limit is also an important consideration.

9. Machines and mechanization : In order to have quality products which will lead to higher productivity of any organization, we need to use advanced machines and mechanize various operations. Modern information methods : The modern information methods help in storing and retrieving needed data for manufacturing, marketing and servicing. Mounting product requirements : Product diversification to meet customers taste leads to intricacy in design, manufacturing and quality standards. Hence, companies should plan adequate system to tackle all these requirements.

10. A systematic approach to development that begins with predefined objectives and emphasizes product and process understanding and process control, based on sound science and quality risk management . Quality by Design

11. Significance of Quality by Design Quality by Design means –designing and developing formulations and manufacturing processes to ensure a predefined quality. Quality by Design requires – understanding how formulation and manufacturing process variables influence product quality. Quality by Design ensures – Product quality with effective control strategy.

12. PRODUCT DEVELOPMENT CYCLE The product development cycle is the process of taking a product from an idea through its market release and beyond. This cycle involves many departments in a company: product managers, developers, designers and others.

13. The product development cycle is a part of the product life cycle. The product development cycle focuses on the planning, development and evaluation of a product and the product life cycle looks at the performance of the product in the market and its market share. The product development cycle consist of the following stages: Plan, Develop, Evaluate, Launch, Assess, Iterate or Kill.

14. ADVANTAGES Product development cycle Easy sales forecasting Competitive Advantage Defined Strategies Decision Making Marketing Target and Positioning

15. DISADVANTAGES Varying Market Conditions Inapplicable to Every Product Fluctuation in Sales Data Effect of Other Elements Delay in Analytics

16. Economics of Quality The economics of quality include  the fact that there are costs to prevention, appraisal, as well as costs of failure . Ultimately the goal is to be able to track the costs and benefits of each to determine the most cost effective solution.

17. Cost of poor Quality Cost of poor quality (COPQ) is defined as the costs associated with providing poor quality products or services. Cost of quality is defined as a  methodology that allows an organization to determine the extent to which its resources are used for activities that prevent poor quality , that appraise the quality of the organization's products or services and that result from internal and external failures. There are three categories :

18. Appraisal costs are costs incurred to determine the degree of conformance to quality requirements. Internal failure costs are costs associated with defects found before the customer receives the product or service. External failure costs are costs associated with defects found after the customer receives the product or service .

19. International Organization for Standardization (ISO) International Organization for standardization certification certifies that a management system, manufacturing process, service, or documentation procedure has all the requirements for standardization and quality assurance. ISO (International Organization for Standardization) is an independent, non-governmental, international organization that develops standards to ensure the quality, safety and efficiency of products, services and systems.

20. What is ISO 9001? It’s a quality management system that can be adopted by any kind of organization. The system is focused towards the meeting of customer requirements and enhancing of customer satisfaction. Keywords: 1. Quality 2. Management system 3. Customer requirements 4. Customer satisfaction

21. Need for ISO 9001 There are too many activities in any organization. Easy to lose track of things and focus. Systemizing of activities is a natural phenomenon . We do it all the time – privately, publicly or commercially. A business faces great risks – big investments, customer expectations, jobs, credibility, etc.

22. Benefits of ISO 9001 • ISO 9001 requires you to: – Plan what you want to do, – Follow that plan, – Monitor, measure and analyze your execution of the plan, – Improve the plan.

23. According to International Organization for Standards (ISO) TQM is a management approach for an organization, centre on quality, based on the participation of all its members and aiming at long-term success through customer satisfaction and benefits to all members of the organization and to the society. It uses strategy, data and effective communications to integrate the quality discipline into the culture and activities of the organization.

24. This system has 5 components or elements and they are applied within your business management. Five-phase guideline for implementing total quality management Leadership Planning Support and operation Performance evaluation Improvement

25. Quality management Total Quality Management

26. Quality management Quality Management is focused not only on product quality, but also the means to achieve it. Quality management therefore uses quality assurance and control of processes as well as products to achieve more consistent quality. Quality management has three main components: Quality control Quality assurance Quality improvement

27. Quality Assurance is the planned or systematic actions necessary to provide enough confidence that a product or service will satisfy the given requirements. Quality Assurance includes regulation of the quality of raw materials, assemblies, products and components; services related to production and management, production and inspection processes. .

28. Quality improvement (QI) is a systematic, formal approach to the analysis of practice performance and efforts to improve performance . Quality Improvement can be distinguished from Quality Control in that Quality Improvement is the purposeful change of a process to improve the reliability of achieving an outcome.

29. Total Quality Management TQM has been defined as an integrated organizational effort designed to improve quality at every level. The process to produce a perfect product by a series of measures requiring an organized effort by the entire company to prevent or eliminate errors at every stage in production is called Total Quality Management.

30. Customer focus Planning process Process management Process improvement Total participation TQM Model

31. Total quality management (TQM) describes a management system wherein  a company attains organizational advancement through a commitment to customer requirements . A company meets those requirements when it empowers every employee in every department to maintain high standards and strive for continuous improvement. Application: creating commitment on the part of the senior management to the application of the TQM approach; designing a total quality strategy (policy, identification of customers and their requirements, definition of quality indexes, setting goals and targets for continual). Application

32. Total Quality Management, TQM, is a  method by which management and employees can become involved in the continuous improvement of the production of goods and services . It is a combination of quality and management tools aimed at increasing business and reducing losses due to wasteful practices.

33. Implementation of TQM Focus on the Customer Employee Involvement Process-centered Integrated System Strategic and Systematic Approach Continuous Improvement Fact-based Decision Making Communications

34. 1. Focus on the Customer : It is important to identify the organization’s customers. External customers consume the organization’s product or service. Internal customers are employees who receive the output of other employees . 2. Employee Involvement : Since quality is considered as the job of all employees, employees should be involved in quality initiatives. Therefore, employees must have the authority to innovate and improve quality.

35. 3. Process-centered : A process is a series of steps that take inputs from suppliers (internal or external) and transforms them into outputs that are delivered to customers (either internal or external). 4 . Integrated System : Integrated system connects business improvement elements in an attempt to continually improve and exceed the expectations of customers, employees and other stakeholders.

36. 5. Strategic and Systematic Approach : A critical part of the management quality is the strategic and systematic approach to achieving an organization’s vision, mission and goals . 6. Continuous Improvement : Continuous improvement means that small, incremental improvement that occurs on a regular basis will eventually add to a vast improvement in quality.

37. 7. Fact-based Decision Making : In order to know how well an organization is performing, data on performance measures are necessary. TQM requires that an organization continually collect and analyses data in order to improve decision making accuracy, achieving consensus, and allow prediction based on past history.

38. 8. Communications : During times of organizational change, as well as part of day to day operation, effective communications plays a large part in maintaining morale and in motivating employees at all levels. Communications involve strategies, method and timelines .

39. The 8 Elements of TQM To be successful implementing TQM, an organization must concentrate on the eight key elements: Ethics Integrity Trust Training Teamwork Leadership Recognition Communication

40. Quality circle Quality circle is a small group to perform quality control activities voluntarily within the small workshop. The small group carries on continuously as a part of company wide quality control activities for self development and mutual development and for control and improvement within the workshop utilizing quality control techniques with all the members participating.

41. Objectives There are number of objectives that can accomplished in the quality circle program. The following examples will give some ideas of the accomplishments that work towards: 1. Self development 2. Mutual development 3. Improvement in quality 4. Improvement in communication and studies 5. waste reduction

42. 6 . Job satisfaction 7. Cost reduction 8. Improvement in productivity 9. Safety improvement 10. problem solving opportunities 11. Team building 12. Link all levels of management and workers together to achieve success 13. Get people more involvement and interest in their work 14. Improve participation 15. Reduce absenteeism and grievances

43. The fishbone diagram is also known as the  Ishikawa diagram , as a tribute to its creator. A fish-bone diagram is one of the seven quality circles (QC) tools. It helps to visualize the potential causes in order to find the root cause of a particular problem. It helps to identify, analyze and improve quality issues. Fishbone diagram, also called as 'cause-and-effect' diagram , is  a tool used to identify the root cause of problems which represents the effect and the factors or causes influencing it . Fishbone diagrams

44. Fishbone diagrams

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